METHOD STATEMENT FOR A/G COLD PIPING INSULATION WORK

TABLE OF CONTENTS

1.0             SCOPE ……………………………………………………………………….3           

2.0             PURPOSE. …………………………………………………………………..…3       

3.0             DEFINITION....…………………………………………………………………...3     

4.0             REFERENCES ……………………………………………………………….…3     

5.0             RESPONSIBILITIES …………………………………………………………...4     

6.0             MATERIAL REQUISITION…………………………………………………......4     

7.0             INSULATION & JACKETING PROCEDURE….………………………..……6

                 

8.0             VALVE & FLANGE BOX INSULATION…………………………….…...…...8

9.0             RESOURCES……..………………………………………………….…..….......8

10.0          HSE REQUIREMENT………………..……………………………….…..……8

11.0          QC REQUIREMENT.………………………………………………….…..........9

12.0          ATTACHMENT……………………………….…………..…………….………9      

1.0         SCOPE

The Scope of work shall be summarized below: -

      I.        To supply and install of basic insulation, cladding and other ancillary’s/fastening material for cold Piping where ever insulation is specified as per project specification.

    II.        Sub-Contractor shall provide all scaffolding where required as per work scope suited insulation installation work.

2.0         PURPOSE

The purpose of this Method Statement is to define responsibility, requirements and the execution procedure for the hot and cold insulation on piping for COMPANY Project.

3.0         DEFINITION

         For the purpose of this specification, the following definitions shall apply:

         Client                :  

Contractor        :   .

                    

                     Project              :  .

         Location            :  

4.0         REFERENCE

   The materials of insulation shall generally meet the requirement of ASTM code, ARAMCO Standards, and PIP. Those not covered in ASTM code shall be conformed to applicable codes, and submitted for Client’s approval. Insulation Specification for COMPANY  Refinery  Project,

      I.        SAUDI ARAMCO ENGINEERING PROCEDURE(SAEP)

    II.        SAUDI ARAMCO ENGINEERING STANDARD (SAES)

   III.        SAUDI ARAMCO STANDARD DRAWINGS

  IV.        PROCESS INDUSTRY PRACTICES

   V.        ASTM SPECIFICATIONS

  VI.        DESIGN CODES & STANDARDS

 VII.        Insulation Details for Cold Piping – AA – 036913-1/2-Rev-06.

5.0         RESPONSIBILTIES

   The responsibilities of the various personnel on the project site are as defined  below:-

1. Management has responsibilities to ensure that insulation work adheres to the recognized standard or code of practice with respect to the project specification, safety, quantity and other requirements.                      

    II.        Site Manager shall be responsible to the Management and for the overall implementation of this method statement for all construction activities carried out.

   III.        QC Operative/QC Inspector shall be responsible for all the inspection and testing works as per approved ITP, the preparation of documents and for maintaining all record.

  IV.        Site Operatives/ supervisor shall be responsible for achieving the stage acceptance of the Inspection & Test Plan. 

   V.        Applicator for direct work shall ensure that they perform the insulation application as per project specification and in accordance with project safety procedure.

  VI.        HSE/Safety Supervisor shall monitor regular safety checks and ensure that the work is carried out in accordance to project safety norms.

6.0         MATERIAL REQUISITION

It shall be the responsibility of the Supervisor to authorize the requisition of the materials required for the relevant items to be insulated using Material Request Issue Form which may consist of:

6.1  Insulation Material

         Cold Insulation- Design Basis Insulation

6.1.1.1    Insulation Material Code as per LEP-OO-GS-0001 with properties meeting to SAEP & SAES.

6.2         Jacketing Material – All Insulation design.

6.2.1  Jacket Material Code as per LEP-OO-GS-0001 with properties meeting to SAEP & SAES.

6.3         Ancillary/Fastening Materials:

6 

6.1 

6.2 

6.3.1  Insulation fastening Material for cold Piping – Filament Tape shall be used up to 4’’ Ø  and SS304 as per A 167 Strap1/2 inch x 0.5mm thick for 6’’ Ø to 36’’Ø and ¾ inch x 0.5mm for 36’’Ø and above  at 250mm spacing.

6.3.2   Jacketing fastening Material for Cold Piping - SS304 as per A 167 Strap 1/2 inch x 0.5mm thick up to 34’’Ø  and ¾ inch x 0.5mm thick for 36’’Ø all metal jackets at 305mm spacing.

6.3.3  Joint sealer shall be applied to all joints of single layer and only to joints of the outer layer of multi – layer applications.

6.3.4  Removable insulation Plugs shall be provided to permit on stream ultra sonic inspection when required by the operating proponent. Plugs shall be vapour tight ultra violet resistant and be such that they can be opened and reclosed without disturbing the adjacent insulation.

6.3.5  Metal sealant shall be RTV Silicone, aluminium or grey color, suitable for continuous service to 204° C and intermittent service to 260° C.

6.4         Vapour Barrier/Vapour Stop  Material – For Cold Insulation type

6.4.1    Before the application of weather proof jacketing, all insulated surface shall be sealed with a vapour barrier mastic or membrane type vapour barrier sheet, as indicated on the material system data sheet.

6.4.2   Membrane type vapour barrier sheet shall be installed without fish mouthing gaps or folds and shall have a minimum 2-inch (50mm) overlap at all joints. 

6.4.3   Vapour barrier mastic with a water vapour transmission rating not exceeding 1 metric perm shall be used to coat insulating cement. Vapour barrier shall have a water vapour transmission rating less than 1.6 metric perms per ASTM E96 when tested at 23°C. Fabric reinforcement of elastomeric coatings is required.

6.4.4   Vapour stops that seal the insulation to the pipe shall be installed at all insulation terminations and changes in configurations. These include, but are not limited to, elbows, flanges, pipe support, instrument connections, un insulated  vents and relief valves

7.0   INSULATION & JACKETING PROCEDURE

7.1       Scope of work & Explanation of Procedure

   The total process consists of surface cleaning, fixing of insulation & cladding material and its securement. This procedure covers stage wise activities including quality control checks for insulation work.

  

7.2       Release Note

   All the areas prior to start of insulation will be officially released to Insulation Sub-contractor. No other activities shall be allowed in the area released for insulation without information to Insulation Sub-contractor. Proper release note has to be provided duly signed by the Contractor concerned engineer / authorized person. The release note receipt should be signed by CONTRACTOR QC or Site-in Charge after physically confirming the readiness of area for insulation.

7.3         Application Of Insulation & Jacketing

7.3.1 General        

·         Insulation shall be applied per all applicable engineering specifications and standard insulation details.

·         It shall be the responsibility of the Supervisor to ensure the insulation and jacket materials are applied correctly including the correct order of layering, and with correct securement/fastening and sealants.

·         Ensure the pipe work test packs released for insulation by the Contractor’s Representative has all previous work including hydrostatic or other testing and touch of painting completed and is in a fit state to insulate.

·         Pipe surface shall be clean, dry and the surrounding area is free of obstacles and debris as per specification.

·         When weep or aeration holes in jacket are required, it will be provided.

·         Thickness selection shall be made from Thickness Tables in the insulation specifications specified for the job.

7.3.2 Insulation Application:

I)         Cold Insulation

·        The surfaces to be insulated shall be dry and reasonably clean prior to the application of the insulation.

·        Check the insulation sections are of correct type, size and thickness including thickness orientation for application as per the project specification.

·        Single layer of insulation shall be applied with longitudinal joints staggered. In multiple layer application all joints of adjacent layers shall be staggered

·        For single layer or the operating temperature less cold than -20 degree C, a joint sealer shall be applied to circumferential and longitudinal butt joints prior to fitting. The mating surfaces of each joint shall be firmly pressed together squeezing our all air bubbles obtaining a firm and complete joint.

·        In multilayer insulation or the operating temperature is colder than -20 degree C, innermost layer shall be applied dry without joint sealant. All other layer shall have joint sealant/ sealer.

·        Vapour stops shall be installed at the insulation termination point location as indicated in project specification. It is not required to apply where a “sealed or adhesive bonded” system is specified or the operating temperature is colder than -20 degree C.

·        Insulation of single or multiple layers shall be secured properly with filament tape / stainless steel 304 banding as specified fastening material in the project specification.

7.3.3 Vapour Barrier Application of Piping

           (For Cold Insulation Application only)

·        Ensure the insulated pipe work is released for the vapour barrier application and the insulation is clean and dry.

·        Cut section of vapour barrier membrane (self-adhesive) and apply over the cylindrical insulated surface with sufficient overlap on circumferential and longitudinal seams and use hand-pressure or roller to smooth tape and ensure adhesion at each overlap.

·        Over irregular insulated surface where not possible to apply vapour barrier sheet, apply tack coat of vapour barrier mastic and lay a reinforcing membrane over the mastic while mastic is still wet. Within 2 or less hour of tack coat apply second coat of mastic. Allow mastic coats to set and dry before application of jacketing.

7.3.4 Jacketing Application

·        Insulated surface shall be weatherproofed by applying fabricated flat metal jackets.

·         Check the material issued is the correct thickness as specified in specification.

·        Jacketing shall be fitted in such a manner as to provide a close fitting assembly without gaps.

·        After the installation of the Jacketing, sufficient clearance to be maintained from nearby spools with or without Jacketing.

Piping

·         Apply sheeting with specified overlaps (horizontal and vertical) with 10mm ball swaged and arranged to shed water all the time..

·          “S” clips (fabricated from bands) shall be used on vertical Piping to prevent telescoping.

·         Secure jacketing with specified fasteners in project specification at the relevant specified pitches.

·         At protrusion the cladding shall be neatly cut to achieve a close fit and sealed with metal sealant.

8.0          Valve & Flange Box Insulation

·         Valve & Flange box shall be Insulated by fabricated PIR

·         Insulation shall be secured properly with filament tape / stainless steel 304 banding as specified fastening material in the project specification.

·         Over irregular insulated surface where not possible to apply vapour barrier sheet, apply tack coat of vapour barrier mastic and lay a reinforcing membrane over the mastic while mastic is still wet. Within 2 or less hour of tack coat apply second coat of mastic. Allow mastic coats to set and dry before application of jacketing.

·         Jacketing cover shall be secure with Banding

9.0         RESOURCES

Machinery Lists

Sl No	Description	No. Required
1	Material storage shed	As required
2	Metal fabrication shed	As required
3	Sheet Metal fabrication machineries such as cutting, rolling, swaging, folding, lock-form etc	As required
4	Electric tools – battery drill, shear cutter etc	As required
5	Hand tools- saw, band tighter etc	As required
6	Pulley- Manual lifting by rope	As required

10.0      HSE REQUIREMENTS

             

·         Comply with all Requirements of company EHS Standards procedure.

·         Task Risk Assessment shall be carried for all critical activities. Risk Assessment to address all the hazards and how to reduce them.

·         Toolbox talks shall be conducted on daily basis prior to commencement of the work.

·         All personnel shall adhere to all relevant procedures set out in the CONTRACTOR/COMPANY HSE plan.

·         Flexible hoses shall be armoured type, and shall be protected against external damage.

·         Work crews and supervisors will attend weekly HSE meetings.

·         All Machinery for the fabrication work should be well-maintained and safe to use.

·         All mandatory PPE (Helmet, Safety Gloves and Shoes) shall be provided all the time.

·         Materials used on this project contain no asbestos and causes no known health hazards either during or after installation. During application, however, the following precautions will be taken.

·         Follow the safety instruction given in material safety data sheet.

·         Protect skin from irritation by wearing loose clothing; wash work clothing separately from other garments.

·         Protect eyes and respiratory tract from airborne product by wearing dust masks and goggles/safety glasses or eye shields.

·         All waste to be disposed-off in safe manner.

·         Unauthorized person not allowed to entire work area.

·         MSDS to be made available.

·         Workers at height 100% tie off and suitable working platforms (Scaffolding).

11.0      QC REQUIREMENTS

·               CONTRACTOR will issue RFI to Contractor wherever applicable as per approved Inspection and Test Plan (ITP) requirement.

·               Upon final acceptance of the installation of the insulation and metal cladding, the QC department shall issue an insulation installation and completion report as per project approved form. 

·               All required documentation will be maintained by QC department.

12.0       ATTACHMENTS

·         Attachment I  SATIP-N-001-01

·         Attachment II JSA for Insulation work